IndianOil R&D Centre, Faridabad

Catalyst Management Solutions for Refining Processes

IndianOil Technologies Ltd.

Contents

Introduction

Catalyst Management

Case Studies

Conclusion

REFINING40%

ENVIRONMENT33%

CHEMICALS27%

Catalyst Demand Scenario

Refining Catalyst Market

FCC40%

ALKYLATION15%

OTHERS5%REF, ISOM

15%

HT, HC25%

Trends in Catalysis

Olden days Last 50 Years Present Future

• Liquid acids Non-selectivity Hazardous Capital, Energy intensive

• Inorganic catalysts Improved selectivity By-products concerns

• Zeolites High selectivity Min. by-products Knowledge base

•New Catalysts Very high

selectivity Clean

process Highly

knowledge based

Relative com

plexity

.

Brute Force

Hammer

Knife

Scalpel

Right choice of Catalyst matters

Growth of FCC Catalysts Formulations

1915 1940 1950 1960 1970 1980 1990 2000

First catalytic cracking AlCl3

First commercial FCC, natural clay

High aluminacatalyst

Y zeolite based catalysts

CO promoter

Nickel passivation (Sb)

USY zeolite

Octane additive

Nickel passivation (Bi)

Sox additiveBCA,, Resid FCC

Com

plex

ity

Catalyst Management

Why Catalyst Management ?

Catalyst/ Additives play key role on unit performance

There are many catalyst vendors offering their products

Right choice of catalyst is very important

Significant yield advantages can be realized through catalyst management

Scope for tailor made catalyst/ additive

Components of Catalyst Management• Catalyst selection

• Change over Decision

• Health monitoring

• Remaining Life Assessment

• Physical Properties Check-up

• Troubleshooting

Services Offered

FCC Catalyst Selection

FCC Additive Selection

Fresh Catalyst Quality Check

Equilibrium Catalyst Monitoring

Trouble Shooting, Technological Solution

Services Offered

HydrocrackingSelection of Catalyst System,

Remaining Life Assessment

Effects of Feedmix Change on Catalysts’ Performance

Optimisation of Hydroprocessing Units

Troubleshooting / Debottlenecking Studies

Services Offered

Reforming

Fresh Catalyst Selection

Catalyst Residual Life Prediction

Catalyst Health Monitoring

Methodology of Selection

Fresh catalyst

Pretreatment

Physico-Chemical Characterization

Standard testing

Performance prediction using model

Pilot plant test

Recommendation for plant trial

Poor

Poor

Poor

Poor

Rej

ect

Indianoil has Rigorous Simulation Models for all these Processes to Support the Catalyst Management

Services

Simulation Models FCC MOD• Kinetics of riser/ regenerator and hydrodynamics of catalyst

stripper

• Extensively used for catalyst performance prediction, process optimization and troubleshooting

HC MOD

• Rigorous hydro-cracking kinetic model based on continuum theory of lumping approach

• Used for simulation studies for process optimization, trouble shooting and catalyst performance assessment

DHDS MOD

• Prediction of total sulfur, concentration of individual S compounds and estimation of chemical Hydrogen consumption

REFMOD MOD

• Model for simulating SR and CCR units

• Plant performance optimization, monitoring and troubleshooting

Simulation Models

Catalyst Development Expertise

• Developed Lotus 24 FCC catalyst formulation– Successfully tried at a refinery

• Novel LPG additive for FCC unit- iMAX– Successfully tried at a refinery– Technology licensed to a catalyst manufacturer

• 4 Indian, 4 USA, 1 Canadian and 1 EU patent granted

Process Improvements and Troubleshooting

FCCFeed Throughput Maximization in Gujarat Refinery Increase in Feed FBP in Gujarat FCC High CRC with High catalyst loss in Gujarat FCC

unit

HydroprocessingTroubleshooting of DHDS & HCU units showing

abnormal behaviourPersistent high diesel pour point problem in existing

HCUCatalyst activity problem in a DHDS unit

Case Studies

Benefits of Catalyst Switchover

1998

Unit Benefits

Mathura Increase in LGP & diesel yield by 1% &1.35%, CLO reduction 3.8% & increase in gasoline octane by 1.5 units

-do- Increase in gasoline & TCO yield by 0.7 % & 2.29%, CLO reduced by 2.89%

-do- Increase in LPG and gasoline by 2.35 and 0.9 wt% respectively, reduction in CLO yields by 2.7%.

Gujarat Increase in gasoline yield by 1%, LPG by 0.7% & reduction in bottoms by 1.7%

-do- Diesel yield increased by 2.5%, CLO yield reduced by 1.5 wt%.

1995

2000

1995

1999

Year

Benefits of Additive Switchover

BCA Mathura Increase in diesel yield by 1 wt%. Reduction in CLO yield by 1.3 wt%, reduction in SOx emission also.

ZSM-5 Mathura Increase in LPG yield by 1 wt %, gasoline by 1.5 %, octane by 1 unit

ZSM-5 Gujarat Increase in LPG yield by 1.58 %, gasoline by 3.48 %, Reduction in CLO yield 1.3 %

1993

1994

1993

Maximization of Middle Distillates HCU Optimization Studies

75

79

83

87

91

15 20 25 30 35 40 45 50 55

1st Stage Conv. (%)

Ove

rall

MD

Yie

ld (w

t %)

Base Case (Design)

- All catalyst systems are more MDs selective than existing one- Excellent products’ properties and low pay back period

Cat-A

Cat-B

Cat-A

0

2E+15

4E+15

6E+15

8E+15

1E+16

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Days on Stream

K

Life : 2 yearsk-EOR

Catalyst Health Monitoring & Remaining Life Assessment Studies for HCU

Conclusion

Catalyst- critical input to refineries Proper Catalyst/ Additive management provides a

competitive edge to refinery operation and profitability Custom catalyst-need of the refinersITL, backed by world class facilities and expert

manpower provide• Catalyst/ Additive management solution • Technical solutions related to revamp, yield optimization,

etc.

Thank You